Systems and methods for mobile molding and bonding

ABSTRACT

A mobile molding system, comprising a vehicle and one or more molds arranged on the vehicle configured for receiving one or more expandable nonwoven substrates, heating said one or more expandable nonwoven substrates so as to cause said one or more expandable nonwoven substrates to expand and fill the one or more molds with one or more expanded nonwoven containing articles of three dimensional shape, and releasing said one or more expanded nonwoven containing articles of three dimensional shape from the one or more molds is provided. Methods for manufacturing three dimensional objects using the mobile molding system are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application62/837,417 filed Apr. 23, 2019, the complete contents of which isincorporated herein by reference.

FIELD OF THE INVENTION

The invention is generally related to a mobile means for providingcomposite nonwoven structures to consumers on site. In particular,compressed nonwoven materials may be expanded within a mold arranged ona vehicle to produce a variety of composite structures includecushioning articles such as furniture (e.g. indoor, outdoor,recreational, etc.), bedding (e.g. mattresses, pillows, toppers, etc.),seating (e.g. automotive, aviation, maritime, etc.) and exercise (e.g.yoga mat, etc.) applications.

BACKGROUND OF THE INVENTION

Textile nonwoven materials (referred to as “nonwovens”) have advantagesover typical polyurethane (PU) foams for use in cushioning materials interms of weight, costs, and performance. By performance, for example,having a nonwoven near the person, i.e., adjacent his or her back orbuttocks in a car seat, adjacent the person's body in a mattress, etc.,provides a more comfortable feel to the person, e.g., it tends to be“cooler” since air can pass through the nonwoven, so that the persondoes not sweat as much. In addition, the nonwoven can provide advantagesin terms of “hardness” and better support factors, making the nonwovenmaterial relatively more comfortable to sit or lay on than a PU foam.

Further, the production of polyurethanes in general has health, safetyand environmental impacts that cannot be neglected. The NationalToxicology Program from the Department of Health and Human Serviceslists toluene diisocyanates (TDI, CAS No. 26471-62-5) as “reasonablyanticipated to be a human carcinogen”. Toluene diisocyanates “are usedprimarily to manufacture flexible polyurethane foams for use infurniture, bedding, and automotive and airline seats”. The production ofpolyurethane also has various hazardous air pollutants emission pointsthat need to be dealt with. Hence, the processing of polyurethane has afew environmental and safety compliance requirements that can be a turnoff in this environmentally conscious era. In addition, polyurethanefoams are not readily recycled and in most cases are destined to residein a landfill at the end of their useful life. In contrast, nonwovenmaterials are completely recyclable and address the current expectationsof today's environmentally conscious consumer.

However, transport of large, expanded nonwoven materials (e.g. amattress) that were produced in a factory can be costly and detrimentalto the environment. There is also a need to provide more customizationopportunities to consumers in regards to the final composite nonwovenproduct.

SUMMARY

Aspects of the disclosure provide a new system and methodology formaking molded components including but not limited to bedding,furniture, automotive seats, airplane seats, boat seats, etc. on site ata consumer's location. Thus, embodiments of the disclosure bring thefactory to a consumer's home and allow the consumer to be involved withmaking key design decisions associated with personalizing the moldedcushioning article. Moreover, significant cost reduction is afforded tothe manufacturer/retailer via shortening of the value creation period,late customization advantages, and supply chain optimization.

One aspect of the disclosure provides a mobile molding system,comprising a vehicle and one or more molds arranged on the vehicleconfigured for receiving one or more expandable nonwoven substrates,heating said one or more expandable nonwoven substrates so as to causesaid one or more expandable nonwoven substrates to expand and fill theone or more molds with one or more expanded nonwoven containing articlesof three dimensional shape, and releasing said one or more expandednonwoven containing articles of three dimensional shape from the one ormore molds. In some embodiments, the system further comprises one ormore of the following provided on the vehicle: one or more expandablenonwoven substrates, a cutting device, a steam generation system, avacuum pump, a refrigeration system, and a heater configured to heat themold. In some embodiments, the nonwoven substrates are verticallylapped, carded nonwoven boards. In some embodiments, the one or moremolds are permanently affixed to the vehicle. In some embodiments, thevehicle is a truck, flatbed, or trailer.

Another aspect of the disclosure provides a method for manufacturingthree dimensional objects, comprising providing the mobile moldingsystem as described herein, placing one or more expandable nonwovensubstrates in the mold, heating the one or more expandable nonwovensubstrates in the mold, wherein the one or more expandable nonwovensubstrates expand in at least one dimension to at least partially fillthe mold and to form at least one object which includes one or moreexpanded nonwoven substrates, cooling the at least one object to providethe at least one object with a shape that at least partially assumes aconfiguration defined by the mold, and opening the mold and retrievingthe at least one object.

In some embodiments, the heating step includes the steps of pressurizingthe mold with a gas; and then directing steam into the mold during orafter releasing some of the gas from the mold. In some embodiments, thegas is air. In some embodiments, the placing step includes placing morethan one expandable nonwoven substrates in the mold. In someembodiments, the placing step includes the step of placing one or morematerials different from the one or more expandable nonwoven substratesin the mold. In some embodiments, the one or more materials are selectedfrom the group consisting of foam, fabric, rubber, metal, metal alloy,polymer, ceramic, and paper materials.

In further embodiments, a method as described herein comprises a step oflaminating one or more expandable nonwoven substrates together to formone or more laminated boards, wherein said placing step is accomplishedby placing said one or more laminated boards in said mold.

In further embodiments, a method as described herein comprises a step oflaminating one or more expandable nonwoven substrates and one or morenon-expanding substrates together to form one or more laminated boards,wherein said placing step is accomplished by placing said one or morelaminated boards in said mold. In some embodiments, the one or morenon-expanding substrates are selected from the group consisting of foam,fabric, rubber, metal, metal alloy, polymer, ceramic, and papermaterials.

In further embodiments, a method as described herein comprises steps offorming one or more laminated boards by either laminating one or moreexpandable nonwoven substrates together, or laminating at least oneexpandable nonwoven substrate together with at least one non-expandablesubstrate; and cutting said one or more laminated boards to one or moreparts of specified sizes, and wherein said placing step is accomplishedby placing said one or more parts in said mold.

In further embodiments, a method as described herein comprises a step ofpositioning a device or material within the mold, wherein the at leastone object adheres to or is otherwise attached to the device or materialafter the at least one object is retrieved from the mold. In someembodiments, the device or material is a frame. In some embodiments, theframe is made of wood, polymer, ceramic, or metal.

In further embodiments, a method as described herein comprises steps ofdrawing a vacuum pressure inside said mold after said heating step andbefore said opening step; and releasing the vacuum pressure before,during, or after said cooling step. In some embodiments, the drawing andreleasing steps are repeated a plurality of times before the openingstep.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a-1f is an exemplary illustration of a mobile molding systemaccording to some embodiments of the disclosure;

FIG. 2 is an exemplary isometric view of a fibrous nonwoven material;

FIG. 3 is an exemplary side view of a vertically lapped fibrous nonwovenmaterial

FIGS. 4a and 4b are schematic side-view illustrations showing that thefibrous nonwoven material is densified and compressed after applicationof heat and pressure, followed by cooling to achieve hardening of thebinder material while the fibrous nonwoven material is in its compressedstate;

FIGS. 5a and 5b illustrate a simplified process methodology where theexpandable material placed is a mold for a mattress is expanded throughapplication of heat to form a mattress (or other desiredthree-dimensional object) which can be retrieved from the mold;

FIGS. 6a and 6b are schematics showing different laminated layups ofexpandable boards.

FIG. 6a shows a board without non-expanding layers, and FIG. 6b shows aboard with one or more non-expanding layers;

FIG. 7 shows a mold with some boards stacked on one another and othersplaced vertically within the mold;

FIG. 8 shows a mold with a frame positioned in the mold with a pluralityof boards therein; and

FIGS. 9a-9c are flow diagrams setting forth improvements in steammolding of expandable substrates according to the present disclosure.

DETAILED DESCRIPTION

With reference to FIGS. 1a-1f , embodiments of the disclosure provide amobile molding system, comprising a vehicle and one or more moldsarranged on the vehicle configured for heating a nonwoven substrate. Anexemplary method comprises the steps of producing thermally bonded,vertically lapped, carded nonwoven materials (i.e. VLAP blanks),laminating and/or compressing VLAP blanks together by applying heat tothe VLAP blanks and cooling them to the proper thickness to produce aVLAP board. VLAP boards are subsequently cut into 2D shapes, placedinside a 3D mold, and with the addition of heat, create a 3D compositestructure. One or more of the foregoing process steps may be performedon the vehicle of the mobile molding system.

Typical composite structures include cushioning articles such asfurniture (e.g. indoor, outdoor, recreational, etc.), bedding (e.g.mattresses, pillows, toppers, etc.), seating (e.g. automotive, aviation,maritime, etc.) and exercise (e.g. yoga mat, etc.) applications.

While lamination and/or compression and/or molding may occur in afactory, embodiments of this disclosure provide the same in a mobilemeans whereby the factory is brought directly to the customer. Numerousconsumer advantages are possible, including custom assembly,personalization of the final product, and zero delivery time. Advantagesto manufacturing include raw material SKU reduction, elimination offinished goods inventory, and waste elimination via streamlined valuecreation. Retailers enjoy the high profit margins associated withcustom, personalized products that were manufactured and delivered atcommodity prices. As with food trucks and mobile dental centers, amobile molding and bonding vehicle may have all the elements of a smallfactory store.

Exemplary vehicles include, but are not limited to, trucks, flatbeds,trailers, or other automobiles or transport devices whether having aninternal combustion engine, an electric motor, or a hybrid system.

One or a plurality of molds of various geometries may be permanently orremovably affixed to the vehicle. Exemplary molds include compressionmolds such as those manufactured by the Gemini Group. The mold may havedimensions configured to produce, e.g. example a mattress (twin, full,queen, king, and other sizes), pillows, toppers, seating, (e.g.automotive, aviation, maritime, etc.), or any other cushioned article.By “permanently affixed”, it is meant that the mold is essentiallyintegrated into the vehicle such that it could not be removed withoutdamage to the vehicle. A mold that is “removably affixed” may includesome means to attach it to the vehicle, e.g. bolts, but could be removedwithout significant damage. In some embodiments, the mold may beprovided with wheels or a conveyer belt to assist in movement around thevehicle.

As described in more detail below, the vehicle may also be equipped withone or more of the following to allow for performing a process asdescribed herein: one or more expandable nonwoven substrates, a cuttingdevice, a steam generation system, a vacuum pump, a refrigerationsystem, and a heater configured to heat the mold. One or more of thecutting device, a steam generation system or unit, vacuum pump,refrigeration system, and heater may be permanently or removably affixedto the vehicle.

Nonwoven materials of various sizes and types may be provided on thevehicle such that cushioning articles may be laminated, bonded, and/ormolded. Additional equipment may be provided on the vehicle to applyadded functionality to the articles (e.g. cooling, anti-allergen,probiotic (odor control), deodorizer (UV activated), antimicrobial,scent, etc.).

The mobile molding and bonding vehicle may integrate numerous portionsof an exemplary nonwoven production process as described herein. In someembodiments, the vehicle allows for one or more of steps laminating,sizing, and molding as described herein.

A manufacturing/molding process compatible with the mobile systemdescribed herein allows for the efficient and low cost manufacturing ofthree-dimensional objects, such as those which might be used in bedding,furniture, automotive, and other industries, using compressed blanks orboards or cut parts formed from nonwovens. The compressed blanks orboards or cut parts are expandable substrates. They may be stacked,placed vertically, placed in a predetermined pattern (e.g., parts on topof one another or offset, etc.) or be randomly distributed in a mold.They may also be laminated to non-expandable substrates with thecomposite part then being distributed in the mold. The expandablesubstrates may be of the same size and shape or be of different sizesand shapes. In addition, expandable substrates of differentconstitutions (e.g., differing in types of fibers, differing density,differing numbers of layers of vertically lapped fibers, differing interms of the presence or absence of non-expansible layers, etc.) may beused in the same mold according to recipes designed to achieve the goalsof the manufacturer. Upon application of heat to a temperature above themelting temperature of the binder material in the expandable substrates,the expandable substrates expand to fill all or part of the mold. Afterapplication of heat, the three-dimensional object is cooled within themold, thereby allowing the binder material to harden. The process thusproduces at least one object with a shape that at least partiallyassumes a configuration defined by the mold.

In some embodiments, a steel, polymer or wood frame may be placed in themold with the expandable substrates. Upon formation of thethree-dimensional object, the three-dimensional object will be adheredor otherwise joined to the steel, polymer or wood frame. Thismethodology may, for example, be used to produce car seats (backs orbases), or seats for trains, planes, and boats. Similarly, thismethodology may, for example, be used to produce bedding (e.g.,mattresses, mattress toppers, pillows, etc.) with the molded, cushionlike nonwoven part being positioned for a person to lay on, and with theframe embedded therein.

The methodology allows for tailoring the attributes of thethree-dimensional object to be produced in any desired fashion. Forexample, depending on the “recipe”, as determined by the constituents ofthe expandable substrates used in the mold, different bedding or seatingfirmness or softness can be produced. For example, laminated boards witha more expandable layer of nonwoven material can be placed at the top ofa mold in order to produce a surface layer of a seat or bed which aperson comes in contact with that is softer and “cooler” due to theability of air to flow through an expanded non-woven material.

The methodology may be used to make three dimensional objects of almostany size and shape. The only limitation appears to be in the shape ofthe mold itself.

In an exemplary embodiment, a three-dimensional object is formed by thefollowing process, any or all of the steps which may be performed on avehicle as described herein. A nonwoven material is formed into blanksby compressing the nonwoven under pressure after melting the bindermaterial. Application of heat during the compressing process can be doneusing hot air, ovens, induction coils, infrared or other means forapplying heat energy. While in its compressed state, the nonwoven iscooled in order for the binder material to re-harden (solidify). Thismay be accomplished simply by removing the heat and/or by blowing coolair through the blanks. The blanks thus formed will typically have aheight dimension substantially less than the nonwoven starting material(e.g., 10% to 50% as thick as the pre-compressed assembly; however,differing thicknesses may be used, with the chief requirement being thatthe compressed dimension is at least smaller than the original dimensionof the nonwoven (be it height, width, or length), and preferably 50%smaller, 60% smaller, 70% smaller, 80% smaller, 90% smaller, etc.

If desired, the blanks can be laminated together to form boards. Or theblanks can be laminated together with non-expandable materials such asfoams, fabric (e.g., knitted material), rubber, metal, metal alloy,polymeric, ceramic, and paper materials. If desired, these boards may becut to form parts which have specific sizes and shapes with a die, CNCmachine, milling machine, scissors, or other suitable device, any or allof which may be provided on a vehicle as described herein.

The blanks, boards, or parts are all “expandable substrates”. In someapplications, the expandable substrates can be deposited in a mold whichis to mold the shape of the desired three-dimensional object. Theadvantage of precisely cut parts is that the fabricator can stack theparts in the mold in an orderly fashion so that upon heating the moldmay be filled (or at least partially filled in a desired area) by anexpanded substrate. However, in other applications, a certain number ofboards might simply be randomly dropped into the mold. Depending on thespecifications of the fabricator, the expandable substrates may beplaced in the mold in particular orders so as to achieve variousattributes for the three-dimensional objects once it is made (e.g.,softer top and sides and firmer middle, etc.). These particular orders,as well as the selection of the nonwoven material that is compressed, aswell as any non-expandable material to be incorporated in the mold canbe considered a “recipe” which will result in the production of threedimensional objects with tailored attributes. For example, differentrecipes would be used for producing firm or soft mattresses or firm orsoft seating.

As discussed above, a frame or other device, or simply other materials,e.g., a metal support screen, etc. may also be incorporated into themold, such that the three dimensional object, once fabricated, adheresto or is otherwise connected to the frame, device, or material. Afterthe mold is partially filled with the expandable substrates, the mold isheated. Application of heat softens (i.e., melts) the binder materialwhich, in turn, allows the stored potential energy of the nonwoven fiberto be released as kinetic energy. That is, the nonwoven fiber expands inat least one dimension (e.g. the dimension it was compressed) backtowards its original configuration in the nonwoven material prior tocompression of the nonwoven. Depending on the fullness of the mold, theexpandable substrate will expand to fill the inside of the mold, and,will adopt the contours of the mold (e.g., flat surfaces, curvedsurfaces, etc.). After expansion, the mold can be cooled (e.g., byapplication of cool air, vacuum or otherwise), and the three-dimensionalobject may be retrieved from the mold.

In some embodiments, steam heating is improved by pressurizing the moldwith compressed air before introducing steam heat. The steam is thenpermitted to flow into the mold at a reduced velocity by exhausting someof the compressed air from the mold. As the compressed air is exhaustedout of the mold, the pressurized steam is permitted to flow into themold. The pre-pressuring process allows for more uniform application ofsteam to the expandable substrates within the mold, and reduces oreliminates damage to the expandable substrates that might otherwise becaused by fast-moving steam and the resultant forces of the same. Inaddition, steam heating is improved by using a vacuum pump system tofacilitate moisture removal, steam removal, and associated heat removalfrom the mold after the application of steam heat to the expandablesubstrates. A further outcome with use of vacuum pump system includesimproved, more-uniform expansion of the expandable nonwoven. It ispreferred that the mold be heated to approximately the same temperatureas the high-pressure saturated steam that is directed into mold.However, the exhausted steam leaves much residual heat in thethree-dimensional object being fabricated, which can make it difficultto remove the object from the mold without damage. By using vacuumdrying, water within the mold which may originate from the steam or fromsome of the materials in the expandable substrate itself may be boiledoff at lower temperatures. This rapid evaporation of residual moisturefrom the expandable nonwoven substrate, due to the application of avacuum pressure inside the mold at the end of application of steam heat,allows for absorbing the latent heat of the product, thereby allowingthe three-dimensional product to be more easily removed from the mold.In addition, application of vacuum pressure also permits a more uniformrise of the expandable nonwoven substrate.

FIG. 2 shows an example of a nonwoven 10 material. In particular, thisdisclosure pertains to the use of what are often termed thermobondednonwoven materials, where a fibrous mass (i.e., one that is not“knitted” or “woven”) has adjacent fibers joined together at varyinglocations by binder material. The nonwoven 10 has height, width, andlength dimensions (i.e., it is three-dimensional in character). A“nonwoven” is a manufactured sheet, web, or batt of natural and/orman-made fibers or filaments that are bonded to each other by any ofseveral means. Manufacturing of nonwoven products is well described in“Nonwoven Textile Fabrics” in Kirk-Othmer Encyclopedia of ChemicalTechnology, 3rd Ed., Vol. 16, July 1984, John Wiley & Sons, p. 72-124and in “Nonwoven Textiles”, November 1988, Carolina Academic Press.Nonwovens are commercially available from a number of manufacturers.

FIG. 3 shows an example of a vertically lapped nonwoven 12 material.Vertical lapping may be performed using methods known in the art, e.g.,as set forth in US 2008/0155787 and U.S. Pat. No. 7,591,049, each ofwhich is incorporated herein by reference. Vertically lapped nonwovensare commercially available from a number of sources. Because of theconfiguration of the lapping, such as is shown in FIG. 3, the nonwoven12 has more support and resilience in the vertical direction.

Fibers which may be used in nonwovens according to the disclosure arewide ranging and include any fibrous network which, when heated in anunmolded environment, will expand at least 5% in any direction (i.e.,expansion in at least one of the vertical, horizontal, or lateraldirections, and possibly all of these directions). The nonwoven can beobtained from a number of commercial sources, and may be in a verticallylapped configuration, cross lapped configuration or randomconfiguration. Vertically lapped (V-Lap) configurations may provide someadvantages in terms of support or comfort when boards/blanks made ofV-Lap are expanded in a mold and they are oriented in a direction whichopposes, for example, the weight of a person's back or buttocks. In thepractice of this invention, V-lap nonwoven is preferably used, and ispreferably compressed to form boards, as will be described below. TheV-lap nonwoven will be generally compressed 50%, 60%, 70%, 80%, 90%,etc. from its original height dimension, and, on subsequent heating willbe able to expand towards, up to, or beyond its original heightdimension.

Nonwovens in the practice of this invention are typically fabricatedfrom a mass of fibers which include binder fibers and one or more otherfibers. The binder fibers have a melting temperature that is below themelting or decomposition temperature of the one or more other fibers,e.g., binder fibers typically have a melting temperature of 80-150° C.(polyesters are typical examples of binder fibers used in the productionof nonwovens (examples of elastic polyester binder fibers include ELK®,E-PLEX®, and EMF type high elastic LMF are commercially available fromTeijin Limited, Toray Chemical Korea Inc., and Huvis Corporation,respectively)). Once the binder fibers are melted, they will generallytack along the outsides of the one or more other fibers, and, oncooling, will harden to produce the nonwoven which is essentially a massof the one or more other fibers with adjacent fibers held together atvarious locations throughout the nonwoven by binder material whichresults from melting and re-hardening of the binder fibers. Thesenonwovens are often referred to as thermobonded nonwovens. Thethermobonded nonwovens in the practice of this invention will have atleast 5% by weight binder material, with up to 95% by weight of the oneor more other fibers. Depending on the needs of the article manufacturerthe binder material may constitute 5-50% by weight of the nonwoven withthe remainder being the one or more other fibers, or the one more otherfibers plus additional materials. For example, the other materials caninclude but are not limited to fire retardant compounds scentedcompounds, antimicrobial compounds or materials (e.g., silver particlesor fibers), polymeric coatings, metal or ceramic particles; etc.Examples of FR chemicals/compounds include, but are not limited to,phosphoric acid and its derivatives, phosphonic acid and itsderivatives, sulfuric acid and its derivatives, sulfamic acid and itsderivatives, boric acid, ammonium phosphates, ammonium polyphosphates,ammonium sulfate, ammonium sulfamate, ammonium chloride, ammoniumbromide.),

The ratio of binder material to the one or more other fibers in thenonwovens used in the practice of the invention can vary widely from 5%by weight binder material:up to 95% by weight one or more other fibers;10% by weight binder material:up to 90% by weight one or more otherfibers; 15% by weight binder material:up to 85% by weight one or moreother fibers; 20% by weight binder material:up to 80% by weight one ormore other fibers; 25% by weight binder material:up to 75% by weight oneor more other fibers; 30% by weight binder material:up to 70% by weightone or more other fibers; 35% by weight binder material:up to 65% byweight one or more other fibers; 40% by weight binder material:up to 60%by weight one or more other fibers; 45% by weight binder material:up to55% by weight one or more other fibers; 50% by weight binder material:upto 50% by weight one or more other fibers; 55% by weight bindermaterial:up to 45% by weight one or more other fibers; 60% by weightbinder material:up to 40% by weight one or more other fibers; 65% byweight binder material:up to 35% by weight one or more other fibers; 70%by weight binder material:up to 30% by weight one or more other fibers;75% by weight binder material:up to 25% by weight one or more otherfibers; etc. Depending on the application, the ratio may range from 5:95to 95:5.

Examples of thermobonded nonwovens which may be used in the practice ofthis invention include but are not limited to:

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polyester fiber. Exemplary types of polyesters which may be usedin the practice of the invention include, but are not limited to PET(polyethylene terephthalate), PTT (polytrimethylene terephthalate), andPBT (polybutylene terephthalate);

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polyacrylonitrile fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polyvinyl alcohol fiber (PVA);

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polytetrafluoroethylene fiber (PTFE), like TEFLON for example;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polyamide fiber, like nylon or perlon for example;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, wool fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, coconut fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, hemp fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, flax fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, jute fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, cotton fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, viscose fiber, like rayon for example;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polyethylene fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, polypropylene fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, Kevlar fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, Basofil fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, Belcotex fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, Nomex fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, O-PAN fiber;

any thermobonded nonwoven made with up to 95% of any denier, any fiberlength, Tencel fiber; and

any thermobonded nonwoven made with up to 95% of a mixture of any of thefibers set forth above or any mixture of fibers with other fibers ofinterest (e.g. silver fibers for providing antimicrobial resistance,basalt fibers, natural fibers (e.g., cotton, ramie, coir, hemp, abaca,sisal, kapok, jute, flax, linen, kenaf, coconut fiber, pineapple fiber,wool, cashmere, and silk), man-made fibers (e.g., polyester, nylon,acrylics, acetate, polyolefins, melamine fibers, elastomeric fibers,polybenzimidazole, aramid fibers, polyimide fibers, modacrylics,polyphenylene sulfide fibers, oxidized PAN fiber, carbon fibers,novoloid fibers, manufactured cellulosic fibers (e.g., rayon, lyocell,bamboo fiber, Tencel, and Modal), and manufactured fire-retardant (FR)cellulosic fibers (e.g., Visil®, Anti-Fcell, Daiwabo's Corona. fibers,Anti-Frayon, Sniace's FR rayon, and Lenzing FR)).

It is also noted that hollow core fibers, e.g., hollow core polyethyleneterephthalate (PET) may be used in nonwovens for use in the practice ofthe invention. In addition, nonwovens useful in the practice of theinvention can be formed using composite fibers, sometimes referred to assheath-core fibers. Binder fibers used to produce nonwovens useful inthe practice of this invention include sheath-core fibers, where thesheath is polyester or some other low melting temperature material.

Examples of nonwovens that would not be usable in the practice of theinvention include:

any thermobonded nonwoven made with a fiber that melts at an equal orlower temperature than the binder fiber's melt temperature; and

any thermobonded nonwoven made with only binder.

FIG. 4a schematically shows that the nonwoven 14 has a height dimensionprior to compression. FIG. 4b schematically shows that aftercompression, the height dimension is substantially smaller, and theproduct from compression 16 is referred to herein as a “blank”. In anembodiment of the invention, blanks are made by heating the nonwoven 14above the melting temperature of the binding material which holds thefibers together and applying pressure to the nonwoven 14 in at least onedimension. After the nonwoven is compressed, the nonwoven is cooled toallow the binding material to re-harden (i.e., solidify) to hold thefibers together in a compressed state called a blank 16. The blank 16might have a height dimension that is one half to one tenth (or evensmaller) the height dimension of the nonwoven in its uncompressed state(e.g., 50%, 40%, 30%, 20%, 10%, etc. the original height dimension). Thefibers in the blank 16 effectively have stored potential energy, as theorientation of the fibers in the blank 16 is not the natural orientationthey are in when in the form of the manufactured nonwoven 14. WhileFIGS. 4A and 4B show compression in the height dimension, it should beunderstood that compression may be performed in any of, or one or moreof, the height, width, and length dimensions. Cooling of the blank 16 toharden the binding material can be performed simply by heat removal, byblowing air through the blank or cooling by other means. All that isrequired, is to have the temperature decrease below the melting pointtemperature of the binder material so that it re-hardens. As will bediscussed below in more detail, blanks such as blank 16 can be laminatedto other blanks and/or to non-expanding materials.

FIGS. 5A and 5B show a simplified production platform to make, forexample, mattresses, according to an aspect of the invention (it beingunderstood that most any other three dimensional object (e.g., carseats, etc.) can be manufactured by the same production platform usingthe same processes. Such a production platform may be arranged on avehicle as described herein.

In FIG. 5A, an expandable substrate 20 (e.g., one or more of a blank, aboard, a cut part, and/or mixtures and multiples of the same) are placedin or dropped into a mold 22. This can be done manually or by roboticarm 24. The mold 22 is shut and then transported, e.g., by conveyor 26,to a heating station 28. For exemplary purposes, the heating station 28is shown as a plurality of pipes which blow hot air and/or steam onto orinto the mold 22; however, the heating station 28 could be an oven orother device which can bring the substrate 20 up to a temperature abovethe melting temperature of the binding material in the expandablesubstrate 20. Once the binding material melts, the expandable substrate20 is permitted to expand back towards its original state. In doingthis, the substrate 20 expands to fill all or part of the mold (in FIG.5b , it can be seen the entire mold was filled). FIG. 5b shows thatafter the mold 22 passes by the heating station 28, it is cooled andopened, and includes an expanded substrate 30. In a mattressmanufacturing or car seat manufacturing process, for example, thesubstrate 30 can expand to fit the inner contours (flat, curved, etc.)of the mold 22. The cooling may be performed at the heating stationusing a blast of cold air or water, vacuum pump system, or simply bywaiting for the mold 22 to cool down. During cooling, the bindingmaterial solidifies as the temperature dips below the melting pointtemperature. This holds the expanded material 30 together as a moldedthree-dimensional article.

FIG. 6A shows an expandable substrate 31 in the form of a three-layerboard. The individual layers 32, 32′, and 32″ can be blanks such asdescribed in FIG. 4b above which are laminated together. The blanks 32,32′, and 32″ can have the same size and shape as shown in FIG. 6A, orthey may have different sizes and shapes depending on the mold and thefabrication requirements for the article to be manufactured. Inaddition, the blanks 32, 32′ and 32″ may have the same fibers andbinders as each other and same ratio of fibers and binders as eachother. Alternatively, and depending on the desires of the fabricator,the blanks 32, 32′ and 32″ may have different ratios of fiberconstitution to binder material or may have different fibers or groupsof fibers in each layer. For example, one could have different blanks32, 32′, and 32″ if there was a desire to have the bottom blank 32″expand less or more than the top blank 32. For example, one or more ofthe blanks 32, 32′ and 32″ could be formed from V-lap nonwoven, whileone or more of the blanks 32, 32′, and 32″ is a nonwoven which is nonV-lap. Alternatively, one or more of the blanks 32, 32′ and 32″ could bemade of a non-expandable material (e.g., fabric, paper, metal, polymer,rubber, ceramic, foam, etc.)

FIG. 6b shows an expandable substrate 33 in the form of a five-layerboard. Like FIG. 6A, expandable substrate 33 has three blanks 34, 34′and 34″, and the blanks 34, 34′, and 34″ may be the same or different interms of size, shape, fiber constitution, and ratio of fibers to bindermaterial (in terms of weight percentage). However, FIG. 6b also includesnon-expandable layers 35 and 35′ which may be the same or different fromeach other. The non-expandable layers can be of almost any materialincluding without limitation foam, fabric, rubber, metal, metal alloy,polymer, ceramic, straw and paper materials. These non-expandable layersmay be chosen to provide different attributes to the three-dimensionalproduct being fabricated (e.g., stiffness, water resistance, fireresistance, magnetism, resistance to radiation, etc.). Each of thelayers may be laminated together to form the expandable substrate 33 inboard form. The expandable substrate 33 of FIG. 6b and the expandablesubstrate 31 of FIG. 6a may be molded in the same way that theexpandable substrate 20 is in FIG. 5 a.

FIG. 7 shows that a plurality of boards 40, 41, 42, 43, 44, 45, and 46(or other expandable substrates) may be placed in a mold 48. They can bepositioned on top of one another, or be oriented vertically. In mold 48,boards 40, 42, and 45 may expand vertically within the mold 48, whilethe vertically oriented boards 41, 43, 44, and 46 may expand laterallywithin the mold 48. The arrangement of boards within the mold can beneatly placed or randomly oriented (e.g., dropped in). FIG. 7 also showsan expandable substrate in the form of a circular “part” 50. The part 50can be made using a die, a CNC machine, scissors, or some other cuttingdevice which can cut a board to any desired shape (e.g., circular,polygonal, or amorphous). The part 50 can be adjacent a board 40, andhave a different size than board 40. FIG. 7 demonstrates that virtuallyany expandable substrate 20 (blank, board, or part) according to thepresent invention can be molded, and that one or more expandablesubstrates can be used in any molding operation and that they can be putin the mold in specific orders (e.g., to achieve specific properties forthe three-dimensional object) or in random order and position. Also,from FIG. 7 it should be clear that non-expandable materials 49 mightalso be placed in areas of the mold 48 where the expandable substrates(e.g. boards 40-46 and part 50 as shown in FIG. 7) will not expand tofill (e.g., a block of foam or piece of wood (see 49) might bepositioned below board 45). These methods advantageously allow one tocustomize the final products to a desired characteristic such as size,feel, and firmness.

FIG. 8 shows a frame 60 extending into a mold 62. Inside the mold aretwo vertically oriented boards 64 and 64′ and two horizontally orientedboards 66 and 66′. As discussed above, boards 64 and 64′ and 66 and 66′may be the same or different in terms of size, shape, constitution offibers, or ratio of fibers to binder material (in terms of weightpercentage). While FIG. 8 shows boards in the mold 62, other forms ofexpandable materials may also be used including parts 50 (see FIG. 7) orblanks (see FIG. 4b ). The two horizontally oriented boards 66 and 66′are positioned respectively above and below the frame 60. The frame 60may be metal, metal alloy, ceramic, wood, or some other non-expandablematerial. Once the boards in FIG. 8 are expanded, the three-dimensionalobject which can be retrieved from the mold 62 will have the framepositioned therein. The frame 60 will adhere to or otherwise be attachedto the expanded substrate.

In one embodiment, the three-dimensional composite is made according toa method comprising the following steps, one or more of such stepsoccurring on a vehicle as described herein:

-   -   1) producing two or more blanks from nonwoven staple fibers and        binder fibers;    -   2) compressing the two or more blanks to a predetermined        thickness in the presence of heat to form a board;    -   3) cutting the board in a pre-determined two-dimensional shape        to make a part; and    -   4) heating the part within a mold to create a three-dimensional        composite.

In one embodiment, one or more specifically selected staple fibers,chosen based on their function (properties) of the final product areblended to form a controlled mass. The controlled mass is made with aspecific weight concentration of the staple fibers and binder fibers.The staple fibers and the binder fibers are dosed such that theconcentration of the binder fiber is from about 90% (wt. %) to about 5%(wt. %), e.g., from about 10%-80% binder fibers, e.g., 10%, 20%, 30%,40%, 50%, 60%, 70%, or 80% (wt. %). In one embodiment, the specificallyselected binder fibers are elastomeric binder fibers and the staplefibers are polyester staple fibers. In another embodiment, thespecifically selected binder fibers are low-melt bicomponent polyesterstaple fiber and the other selected staple fibers are polyester staplefibers. In yet another embodiment, there are two specifically selectedbinder staple fibers, i.e. a low-melt bicomponent polyester staple fiberand an elastomeric binder fiber, with another specifically selectedstaple fibers.

In some embodiments, other fibers in addition to the staple and binderfibers may be included in the blend. For example, additional cellulosicfibers such as rayon or viscose may be included. In some embodiments,fibers that have been treated to exhibit one or more properties such ashydrophobicity, hydrophilicity, and antimicrobial properties areincluded.

In particularly preferred embodiments, the nonwovens thus made are V-lapnonwovens.

In one embodiment, one or multiple blanks are laid on top of oneanother, heated, then compressed, e.g. laminated, and cooled, e.g. viaambient air, to a consolidated desired thickness to make the boards. Theblanks may be heated to a temperature of about 300-500° F., e.g.300-350° F., or 390-425° F. In yet another aspect, the boards have athickness less than the sum of the thickness of the blanks. In a furtherembodiment, the boards are cut into two-dimensional shapes to make theparts. The boards are cut into two-dimensional shapes using for examplea die board and a hydraulic press or an automated 2-axis CNC cutter.

FIGS. 9a and 9b show various improvements when steam heating is used toheat the expandable substrates placed or dropped in a mold. Theprocesses involve introducing steam directly into the mold, as opposedto heating up the outside of the mold as is shown in FIG. 5a . Likenumerals in the two figures denote like elements.

With particular reference to FIG. 9a , the mold is preferably heated tothe same or approximately the same temperature as the steam that will beintroduced into the mold at step 100. Pre-heating the mold will ensurethat when the steam is used to heat up and expand the expandablesubstrates placed in the mold, the heating will be more uniform fromoutside to inside, and thus the expansion of the expandable materialswill be more uniform. Moreover, if the temperature of the mold is lessthan the temperature of the steam, then the steam will condense as itencounters the mold surface, resulting in a loss of available energy todeliver to the nonwoven expandable substrate, and wetting the nonwovenexpandable substrate with liquid water. As indicated at step 102, theexpandable substrates are placed in the pre-heated mold. As discussedabove, the expandable substrates could be one or more blanks, one ormore boards, one or more cut parts, and mixtures of the same. As notedabove, the expandable substrates charged into the mold can be the sameor different. Use of different boards according to prescribed recipes ofthe manufacture can be used to make three-dimensional objects havingdifferent properties at different locations on the object (e.g., aharder center with a softer side or top surface, etc.). At step 104 themold is closed, and at step 106 all valves to the mold (e.g., steaminlet, compressed air inlet, exhaust outlet, etc.) are closed.

As indicated in step 108, the inside of the mold is pressurized withcompressed air to match the steam pressure of the steam that will beintroduced into the mold. This is accomplished by opening a valve on themold and pumping in compressed air. Other gases may also be used topressurize the inside of the mold. Once pressurized, as can bedetermined by a gas pressure meter or by other means, the valve for thecompressed air is again closed at step 110.

The valve connecting the steam into the mold cavity, which can beanywhere on the mold cavity including the upper, lower, and sideportions of the cavity is slowly opened at step 112. Because of thepre-pressurization of the mold cavity with compressed air, steam willnot immediately flow into the mold. That is, the pressure of the steamwill be counter-balanced by the pressurized air in the mold. To have thesteam enter the mold, the exhaust valve in the mold cavity is slowlyopened to a desired position and duration at step 114. This permitssteam to enter and flow through the inside of the mold, thus exposingthe expandable substrates therein to steam heat, and allowing for theirexpansion. Because the entry of the steam is conducted in a controlledfashion, the expansion of the expandable substrates is more uniformwhich is desirable for making quality three-dimensional objects.

After introduction of the steam the valves are closed at step 116, andthe mold is held for a period of time at step 118 during which theexpandable substrates expand to fill all or part of the mold. After therequisite time, the steam is exhausted from the mold at step 120, themold is opened at step 122, and the three-dimensional object isretrieved from the mold at step 124.

Not to be bound by theory, the core idea (based upon the conservation ofenergy, the continuity equation, the Bernoulli principle, and Newton'ssecond law of motion) addresses the fluid dynamics behavior occurring inthe mold (during the molding process) and adds control of parameterswhich are presently not managed with the current methods ofmanufacturing; slowing the overall rate that energy is added to andexhausted from the system. Rather than allowing high pressure steam toenter the mold at atmospheric pressure, FIG. 9a shows pressurizing themold first with compressed air to an internal mold pressure that's equalto that of the steam heat. Given that the input pressure of the steam tothe mold is equal to that within the mold, steam will not flow until apressure differential is initiated. With a slight opening of the exhaustvalve the pressure within the mold may be slowly lowered and steam willbegin to flow with a substantially reduced velocity of the steam heat,enabling a more-uniform application of energy to the nonwoven expandablesubstrate. Exemplary advantages of this approach to steam moldingincludes a more uniform rise of the expandable substrate, completefilling of the mold cavity subsequent to expansion of the nonwovensubstrate and elimination of damage to the expandable substrate causedby the fast-moving steam and the forces resultant to the same.

FIG. 9b is identical to FIG. 9a except for the addition of steps 130,132, and 134. FIG. 9b addresses the problem of the steam leavingsignificant residual heat in the expandable substrate in the mold. It isaddressed with the use of a vacuum pump system to facilitate removal ofmoisture, steam and the associated heat. It is known that the additionof steam into an environment with lower temperatures will cause thesteam to condense to liquid water. Given this, steam molding parameterstypically call for mold temperatures that are equal to the temperatureof high-pressure, saturated steam. While addressing the condensationissue, the exhausted steam leaves much residual heat in the part, makingit difficult to remove the article without damage.

As can be seen from FIG. 9b , after, or concomitantly with exhaustingthe steam pressure from the mold, a vacuum pump is used to pull a vacuumin the mold at step 130. After a vacuum is pulled, the mold is held witha vacuum pressure for a period of time at step 132. Then, at step 134,the vacuum pump is stopped and the mold is returned to ambient pressurebefore it is opened at step 122 and the part is removed at step 124.Vacuum drying is based on the phenomenon that as the vapor pressure on aliquid reduces, its boiling point reduces. The boiling point of a liquidis defined as the temperature at which the vapor pressure of the liquidis equal to the external pressure. When the pressure above a liquid isreduced, the vapor pressure needed to induce boiling is also reduced,and the boiling point of the liquid decreases. By reducing pressure, theprocess is permitted to boil off water at lower temperatures. This rapidevaporation of residual moisture from the expandable nonwoven substrate(due to the low surrounding pressure), absorbs the necessary latent heatfor the phase change from the product itself. The latent heat requiredfor evaporation is obtained mostly from the sensible heat of the productand because of the evaporation of residual moisture, the temperature ofthe product is reduced, and the product can be cooled down to a desiredtemperature that enables safe removal from the mold. A more uniform riseof the expandable nonwoven substrate is anticipated in a mannerconsistent with more uniform rising of a loaf of bread (noted by thosein that industry who utilize vacuum cooling for baked goods); this beinga desirable outcome in addition to solving the demolding problem.

FIG. 9c is similar to FIG. 9b , but includes additional steps forpressurizing the mold multiple times (208, 210, 212, and 214),exhausting steam pressure (216), and applying vacuum pressure to themold multiple times (218, 220, 222, and 224). It has been found that thenonwoven expandable substrates will expand more uniformly and fullywithin the mold by one or more of controlling pressurization of the moldwhen applying steam inside of the mold, and controlling the applicationof a vacuum pressure inside the mold prior to removal of the part fromthe mold.

In FIG. 9b , it was noted that pre-pressurizing the mold with a gas(e.g., compressed air) to match the steam pressure set point at step 108can provide a number advantages when expanding the expandablesubstrates. FIG. 9c shows a specific process which will achieve theseobjectives in an alternate, orderly fashion. Specifically, at step 208,the mold is slowly pressurized with the steam to a specified steampressure set point. This can take place in the entire mold cavity, ifthe expandable substrates are to fill the entire cavity, or just in thelower or upper mold, for some applications, such as when the substrateswill only be expanded in the upper or lower mold. At step 210, thepressurized mold is held for a period of time under the desiredpressure. Then, at step 212 the pressure is reduced by preferably 20% to80% of the desired set point by, for example, exhausting a portion ofthe steam from the mold. This process is repeated 2-6 times at step 214.This process allows the manufacturer greater opportunity to add steamenergy to the mold which assures better and more uniform expansion ofthe expandable substrates when the steam pressure is applied.

At step 216 in FIG. 9c , the steam pressure is exhausted out of themold, such as through a port in the upper mold. This is permitted untilthe mold achieves ambient pressure therein. Then, at step 118, the moldis held, at ambient pressure for a period of time before performingvacuum operations.

In FIG. 9c , a vacuum pump operation is performed at steps 218, 220,222, and 224 prior to the mold being opened. As discussed in connectionwith FIG. 9b . the vacuum can pull excess heat remaining in the moldfrom the steam, as well as water or other liquids which may be presentin the mold. At step 218 a vacuum is pulled on the inside cavity of themold. This can be achieved through a port in the upper mold or by othermeans. At step 220, the vacuum pressure is maintained for a period oftime once a selected vacuum pressure inside the mold is achieved. Thissubjects the now expanded expandable substrates to a vacuum pressurewhich may be useful in helping more uniformly expand the nonwovenmaterial. At step 222, the pumping is stopped and the mold is permittedto return to ambient pressure. At step 224, the entire process isrepeated, for example, 2-6 times with the vacuum being applied, the moldbeing held under vacuum pressure for a period of time, and the vacuumpressure being exhausted from the mold. The application of the vacuumpressure helps remove contaminants such as water, other fluids, gases,debris, etc., which may be present in the mold. In addition, the vacuumpressure helps remove excess heat from the mold. Finally, the repetitiveapplication of vacuum pressure leads to a more uniform product beingproduced in the mold.

FIGS. 9a, 9b and 9c all represent different potential processes that canbe implemented alone or in combination with other processes when moldingthe self rising expandable substrates on a vehicle as described herein.FIG. 9a illustrates slowing the rate that steam is allowed to enter themold by first pressurizing the same with air. FIG. 9b illustrates addinga vacuum pump to the end of the cycle to facilitate evaporative coolingand more uniform rise of the board. FIG. 9c shows using a series of‘steam blasts with partial steam exhaust cycles’ to increase the amountof energy that's added to the system and a series of vacuum cycles toincrease the rate of removal of heat and moisture.

To perform efficient vacuum cooling, there are several considerations tobe followed to ensure that that the vacuum chamber, vacuum pump, andrefrigeration system, all of which may be arranged on a vehicle asdescribed herein, work together to achieve optimum and efficient coolingresults.

Vacuum Chamber: The vacuum chamber is used to hold the product to becooled. In the described methodology, the vacuum chamber is the moldthat contains the expandable nonwoven substrate.

Vacuum Pump: The vacuum pump evacuates the air contained in the vacuumchamber (i.e. the mold). The evacuation of hot, moist air causes apressure drop inside the mold, resulting in a temperature drop withinthe product (i.e. expanded nonwoven article) and inside the chamber dueto evaporative cooling. Evaporative cooling is achieved as the moisturein the product boils off under the reduced pressure caused by the vacuumpump within the vacuum chamber. The air to be evacuated from the vacuumchamber includes the air surrounding the product and the air that is inempty spaces found within the open structure of the expanded nonwovenarticle. The vacuum system should be sized adequately to lower theatmospheric pressure in the vacuum cooler at an acceptable rate. Avacuum system that is oversized can add extra, unnecessary equipment andoperational costs, while an undersized system may not achieve cycle timerequirements.

Refrigeration System: The refrigeration system for the vacuum cooler isused to re-condense the heat laden vapor that is boiled off from theproduct being cooled. This allows the vacuum system to continue to lowerthe atmospheric pressure inside the chamber, resulting in furthercooling of the product. The re-condensing of the vapor also prevents themoisture from getting into the vacuum pumps. Excess moisture in vacuumpumps has the potential to re-condense in the lubricating oil in thepumps. This leads to reduced performance and speed when it comes toevacuating the chamber and will also shorten the operating life of thevacuum pumps. As evident from the explanation above, it is required thateach of the functional components of a vacuum cooling system beengineered and sized appropriately to prevent them from working againsteach other. A balanced system is required for a vacuum cooler to performits job efficiently, with acceptable cycle times, and in acost-effective way.

It is noted that, as used herein and in the appended claims, thesingular forms “a”, “an”, and “the” include plural referents unless thecontext clearly dictates otherwise. It is further noted that the claimsmay be drafted to exclude any optional element. As such, this statementis intended to serve as support for the recitation in the claims of suchexclusive terminology as “solely,” “only” and the like in connectionwith the recitation of claim elements, or use of a “negative”limitations, such as “wherein [a particular feature or element] isabsent”, or “except for [a particular feature or element]”, or “wherein[a particular feature or element] is not present (included, etc.) . . .”.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range, is encompassed within the invention. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges and are also encompassed within the invention, subject toany specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either orboth of those included limits are also included in the invention.

As will be apparent to those of skill in the art upon reading thisdisclosure, each of the individual embodiments described and illustratedherein has discrete components and features which may be readilyseparated from or combined with the features of any of the other severalembodiments without departing from the scope or spirit of the presentinvention. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

The invention is further described by the following non-limitingexamples which further illustrate the invention, and are not intended,nor should they be interpreted to, limit the scope of the invention.

EXAMPLES Example 1

To make an automotive seat cushion with a firm feel, three layers of 30%by weight of TEIJIN 6 dtex×64 mm elastomeric binder staple fiber and 70%by weight of HUVIS 3d×51 mm hollow dry conjugated crimp polyester staplefiber, with 550 gram per square meter of the density and 30 mm ofthickness were stacked one top of each other. The three layers wereheated, compressed and cooled into one board with a thickness ofapproximately 30 mm. The board was cut to fit inside the outerdimensions of the seat cushion mold to make a part. The part was thenplaced inside the cushion mold cavity and the mold was closed and heatedto 400° F. for 150 min, cooled at ambient temperature for 90 min forafford the formed automotive seat cushion.

Example 2

To make an automotive seat cushion with a plush feel, two layers of 30%by weight of TEIJIN 6 dtex×64 mm elastomeric binder staple fiber and 70%by weight of HUVIS 3d×51 mm hollow dry conjugated crimp polyester staplefiber, with 550 gram per square meter of the density and 30 mm ofthickness were stacked one top of each other. The two layers wereheated, compressed and cooled into one board with a thickness ofapproximately 20 mm. The board was cut to fit inside the outerdimensions of the seat cushion mold to make a part. The part was thenplaced inside the cushion mold cavity and the mold was closed and heatedto 400° F. for 150 min, cooled at ambient temperature for 90 min forafford the formed automotive seat cushion.

Example 3

To make an automotive seat backrest with stiff B-side, two (2) layers of550 grams per square meter density, 30 mm thickness, 30% by weight ofTEIJIN 6 dtex×64 mm elastomeric binder staple fiber and 70% by weight ofHUVIS 3d×51 mm hollow dry conjugated crimp polyester staple fiber werelaid on top of one (1) layer of 400 grams per square meter density, 20mm thickness, 30% by weight of HUVIS 4d×51 mm low-melt bicomponentcoPET/PET sheath/core sheath melting point at 110° C. polyester staplefiber and 70% 6d×51 mm regenerated mechanical crimp polyester staplefiber. The three layers were heated, compressed and cooled to form aboard of a thickness of approximately 30 mm. The board was cut to fitinside the outer dimensions of the seat backrest mold to make the part.The part was placed inside the seat backrest mold cavity and the moldwas heated to 400° F. for 150 min, then cooled at ambient temperaturefor 90 min to afford the formed automotive backrest with stiff B-side.

We claim:
 1. A mobile molding system, comprising: a vehicle; and one ormore molds arranged on the vehicle configured for receiving one or moreexpandable nonwoven substrates, heating said one or more expandablenonwoven substrates so as to cause said one or more expandable nonwovensubstrates to expand and fill the one or more molds with one or moreexpanded nonwoven containing articles of three dimensional shape, andreleasing said one or more expanded nonwoven containing articles ofthree dimensional shape from the one or more molds.
 2. The system ofclaim 1, further comprising one or more of the following provided on thevehicle: one or more expandable nonwoven substrates, a cutting device, asteam generation unit, a vacuum pump, a refrigeration system, and aheater configured to heat the mold.
 3. The system of claim 2, whereinthe nonwoven substrates are vertically lapped, carded nonwoven boards.4. The system of claim 1, wherein the one or more molds are permanentlyaffixed to the vehicle.
 5. The system of claim 1, wherein the vehicle isa truck, flatbed, or trailer.
 6. A method for manufacturing threedimensional objects, comprising: providing the system of claim 1;placing one or more expandable nonwoven substrates in the mold; heatingthe one or more expandable nonwoven substrates in the mold, wherein theone or more expandable nonwoven substrates expand in at least onedimension to at least partially fill the mold and to form at least oneobject which includes one or more expanded nonwoven substrates; coolingthe at least one object to provide the at least one object with a shapethat at least partially assumes a configuration defined by the mold; andopening the mold and retrieving the at least one object.
 7. The methodof claim 6, wherein said heating step includes the steps of pressurizingthe mold with a gas; and then directing steam into the mold during orafter releasing some of the gas from the mold.
 8. The method of claim 7,wherein the gas is air.
 9. The method of claim 6, wherein the placingstep includes placing more than one expandable nonwoven substrates inthe mold.
 10. The method of claim 6, wherein the placing step includesthe step of placing one or more materials different from the one or moreexpandable nonwoven substrates in the mold.
 11. The method of claim 10,wherein the one or more materials are selected from the group consistingof foam, fabric, rubber, metal, metal alloy, polymer, ceramic, and papermaterials.
 12. The method of claim 6, further comprising the step oflaminating one or more expandable nonwoven substrates together to formone or more laminated boards, and wherein said placing step isaccomplished by placing said one or more laminated boards in said mold.13. The method of claim 6, further comprising the step of laminating oneor more expandable nonwoven substrates and one or more non-expandingsubstrates together to form one or more laminated boards, and whereinsaid placing step is accomplished by placing said one or more laminatedboards in said mold.
 14. The method of claim 13, wherein the one or morenon-expanding substrates are selected from the group consisting of foam,fabric, rubber, metal, metal alloy, polymer, ceramic, and papermaterials.
 15. The method of claim 6, further comprising the steps of:forming one or more laminated boards by either laminating one or moreexpandable nonwoven substrates together, or laminating at least oneexpandable nonwoven substrate together with at least one non-expandablesubstrate; and cutting said one or more laminated boards to one or moreparts of specified sizes, and wherein said placing step is accomplishedby placing said one or more parts in said mold.
 16. The method of claim6, further comprising the step of positioning a device or materialwithin the mold, wherein the at least one object adheres to or isotherwise attached to the device or material after the at least oneobject is retrieved from the mold.
 17. The method of claim 16, whereinthe device or material is a frame.
 18. The method of claim 17, whereinthe frame is made of wood, polymer, ceramic, or metal.
 19. The method ofclaim 6, further comprising drawing a vacuum pressure inside said moldafter said heating step and before said opening step; and releasing thevacuum pressure before, during, or after said cooling step.
 20. Themethod of claim 19, further comprising repeating the drawing andreleasing steps a plurality of times before the opening step.